NPRA Cat Cracker Transcript

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Transcript of NPRA Cat Cracker Transcript


CAT CRACKER SEMINAR TRANSCRIPT August 8-9, 2000 Houston, Texas

N A T I O N A L P E T R O C H E M I CAL & R E F I N E R S A S S O C I A T I O NSUITE 1000 # 1899 L STREET, N.W. # WASHINGTON, DC 20036



NPRA CAT CRACKER SEMINAR AUGUST 8-9, 2000 HOUSTON, TEXASTABLE OF CONTENTS Panelists..................................................................................... ii Refractory, Materials, Internals, Expansion Joints, and Slide Valves .........................................................................................3 Rotating Equipment................................................................32 Turnaround/Maintenance/Inspection....................................40 Process/Performance Related Issues......................................51 Exhibitors ................................................................................61

IMPORTANT NOTICEThe information and statements herein are believed to be reliable but are not to be construed as a warranty or representation for which the participants assume legal responsibility. Users should undertake sufficient verification and testing to determine the suitability for their own particular purpose of any information or products referred to herein. NO WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS MADE. Nothing herein is to be taken as permission, inducement, or recommendation to practice any patented invention without a license.



Larry Carper

FCCU Mechanical Equipment Consultant BP Amoco Naperville, IL President Shared Systems Technology Thorofare, NJ Engineering Advisor Reliability & Process Safety Westhollow Technology Center Equilon Enterprises LLC Houston, TX FCC Technical Services Manager Kellogg Brown & Root Houston, TX Reliability Engineer Sunoco, Inc. Toledo, OH Process Engineer Williams Refining LLC Memphis, TN

Frank DeMartino

Mike Drosjack

C. J. Farley

Jim Marlowe

Spence Cousar


2000 Cat Cracker SeminarAdams-Mark Hotel Houston, TX August 8-9, 2000

CRAIL: Good afternoon. Id like to welcome you to the 2000 Cat Cracker Seminar. I want to thank you all for coming. My name is Jerry Crail of Equilon LLC and I am the chairman of this years seminar. First, I want to welcome everybody. I think we have a record turnout this year, which is great. I hope everyone finds this seminar as fruitful as it has been in the past, and after looking at the agenda I am sure it will be. To start with, I'd like to introduce some of the committee members - the ones that have worked very hard to put on this seminar. They are Jon Carlson of Koch Petroleum, Fred Collier of Williams Energy, Shailendra Gupta of BP, Pat Lysaght of Marathon Ashland, and Charlie Pauls of Cooperative Refining. If you're here, could you stand up? I'd like to thank them again for their fine work. [applause] I'd also like to thank the NPRA staff that has worked very hard to make all of these arrangements for the meeting facilities and the tabletop area. They are Jeff Hazle, Yvette Brooks, Stacy Lane and Kelly Healy. If you're around, could you stand up? [applause] Thank you. I also want to thank the exhibitors. This is the first year of having a larger exhibit hall, and I want to thank them for putting on, from what I can see, a fantastic tabletop show, and I hope you all appreciate it. I think their participation is one of the things that will really make this conference one that's worthwhile to everyone. I'm looking forward to the agenda. We're going to start off today with a Q&A Session, and we have the panelists here. We'll talk to them in a minute. Tomorrow, we will have the workshops and there will be a series of them with six starting in the morning, and six more in the afternoon. As you will notice, some of them are repeated, which will enable people to go to different workshops. The tabletop exhibit will be open this evening after the Q&A Session. It will also be open tomorrow morning, and tomorrow morning we will have coffee, and that will only be coffee - there will not be any continental breakfast. The tabletop will also be open tomorrow at lunch for you to see all of the fine things they have out there. Also, the transcripts of the last two Cat Cracker Q & A Sessions are available. For those of you that attended the meeting two years ago, you should have received your copy by mail within the last week. If you have not received the 1996 or 1998, you can pick them up at the NPRA registration desk. With that, I'd like to go ahead and start the conference and turn it over to Jeff Hazle for the Q&A. HAZLE: Thank you, Jerry, for introducing the Q&A Session. We're employing the usual Q&A format where we solicit questions from past attendees of these conferences. The Program Committee puts together a panel of experts, who then edit those questions submitted to NPRA and select the ones that they will use in the session. The Panelists then prepare their responses, often consulting other people in the places where they work, and put their answers together. This 1

year, we have tried to organize the answers as much as possible in the following way: The first responder will give some background on the question. The second responder will describe how the problem was addressed initially, and then the third responder, if there is one, will talk about how the solution to the problem has evolved as technology has advanced. We have a different stage setting this year. Hopefully, its more informal, and more conversational. It is intended to represent a dialogue with you, the attendees, and the panel. As usual, the session will be recorded and a transcript will be made. For that reason, we ask that you use the microphone when you address questions to the panel. We have microphones in both aisles and one in the back. We also have people who will be carrying the microphones to you, so if you have a question to ask of the panel, raise your hand, and somebody will bring the microphone to you. When they do that, if you would, please state your name and affiliation, and hand a business card to the microphone handler, because when we finish the transcript, we will mail it out to everybody who speaks, and you will have a chance to edit your comments, if necessary, or make changes - make sure we understood what your question was. As usual, there is a disclaimer for this. The panel is representing their experiences. There is no legal responsibility or liability that goes along with their answers. Anything that you hear here, of course, you need to test to see whether or not its appropriate for your own facility. With that, we will introduce the panelists. I will ask each of them to describe the kind of FCC units that they work with, and then well go to the questions. Next to me is Mike Drosjack with Equilon. Mike? DROSJACK: Hi. Im with Equilon Enterprises, which was formed by Shell and Texacos refining arms a couple of years ago. Im in the Westhollow Technology Center, which is up the road here, in Houston, and we provide support to the various refining locations we have. My particular function is providing support in the rotating machinery area. And in our company right now, we have eight Cat Crackers scattered around the country from Delaware City to Louisiana to Houston, and have a little bit of everything in that package. HAZLE: The next panelist is Spence Cousar. Hes a late fill-in for Jeff Warmann at Williams Energy. They had some problem at the refinery, and Jeff couldnt make it, so Spence is filling in at the last moment. Spence, what do you have at Williams? COUSAR: Im a process engineer at the Williams refinery in Memphis, TN. We have a 75,000 bbd FCC that processes 100% atmospheric tower resid. We completed an FCC revamp in November 1999. We replaced both our reactor and regenerator and installed UOPs VSS catalyst separation technology in both vessels. HAZLE: Thanks. The next panelist is C. J. Farley of Kellogg Brown & Root. FARLEY: I joined KBR in 1997; prior to that, I worked for a major refining company for just over 7 years. My job is to perform FCC technical service work for KBR, which means I travel around the world to visit different locations where we have projects as well as heading to places where we have extended service agreements. The units I typically interface with are Kellogg/KBR 2

designs that are anywhere from five years to thirty years old. I also work with a good number of UOP geometries, such as side-by-side, stacked and high-efficiency designs. HAZLE: The next panelist is Jim Marlowe of Sunocos Toledo refinery. MARLOWE: Ive been with the Sun Toledo Refinery for about ten or fifteen years, and we have a 150,000 bpd fuel facility refinery, and our Cat Cracker is around a 60,000 bpd. Before that I had service with Amoco and with ARCO. HAZLE: Next is Larry Carper, who works in BP Amocos Refining Technology Group in Naperville, Illinois. CARPER: BP Amoco currently has 22 Fluid Units utilizing various designs and technologies throughout the world. Some of the units are gas oil units and some are resid units. My exchange today will focus on experience with the heritage Amoco units as my exposure to the heritage BP units is limited. I have over 23 years experience within the company, and shortly will become a free agent. HAZLE: Alright, last is Frank DeMartino. DEMARTINO: I don't have a Cat Cracker, but I've been working with FCCUs for 25 years. I'm the president of Shared Systems Technology. I've been involved in at least 50 Cat Cracker installations and I've probably seen the full spectrum of FCCU technology. I don't work just for one company, I work for many companies. So that's why I am glad to come here and try to share some information with you. HAZLE: Thank you panelists. Lets go to the first question. Following each question, after the panelists responses, I